Disk drive suspension assembly having a partially flangeless load point dimple

ABSTRACT

Various embodiments concern a suspension assembly of a disk drive. The suspension assembly includes a load beam comprising a major planar area formed from a substrate. The load beam further comprises a window in the substrate, a dimple formed from the substrate, and a flange. The flange is a region of the major planar area that extends partially around the dimple but does not extend along an edge of the dimple. The edge of the dimple is adjacent to the window. The dimple is in contact with the flexure. A HAMR block or other element can extend through the window. The lack of a full flange can minimize the necessary clearance between the dimple and the HAMR block or other element and thereby allow the window to be enlarged to accommodate the HAMR block or other element.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Pat. No. 8,717,712, whichissued on May 6, 2014 and which claims the benefit of U.S. ProvisionalApplication Ser. No. 61/846,492 filed on Jul. 15, 2013, and entitledDISK DRIVE SUSPENSION ASSEMBLY HAVING A PARTIALLY FLANGELESS LOAD POINTDIMPLE, to each of which the benefit of priority is claimed, and each ofwhich is incorporated herein by reference in its entirety for allpurposes.

TECHNICAL FIELD

The present disclosure relates generally to a head suspension assemblyof a disk drive. In particular, the present invention concerns a loadpoint element having a partial flange.

BACKGROUND OF THE INVENTION

Disk drives operate by reading and/or writing data to sections of one ormore spinning disks housed within the disk drive. One or moretransducers can be moved along each spinning disk to allow the one ormore transducers to interface with different areas of the disks in arapid manner. The one or more transducers are held over the disk by ahead suspension assembly. The one or more transducers typically writeto, and read from, the disk media magnetically. The one or moretransducers are supported on the head suspension by a slider. Theproximity of the slider to the surface of the disk, and the movement ofair generated by the spinning of the disk, causes the slider to “fly”over the disk surface on an air bearing. The slider is suspended by aspring mechanism and is gimbaled to pitch and roll as needed whileflying over the surface of the disk.

There is a constant need in the art to increase the quantity of datathat can be stored in a disk drive. However, increasing the density ofstored data further limits the disk area dedicated to storing each bit,which eventually meets the superparamagnetic limit of the disk media.One emerging technology for increasing the performance of disk drives isenergy-assisted magnetic recording (EAMR). EAMR uses various types ofenergy to selectively change the coercivity of the disk media. Varioustypes of EAMR exist, such as heat-assisted magnetic recording (HAMR) andmicrowave assisted magnetic recording (MAMR). HAMR technology, forexample, allows the use of disk media that has higher magnetic stabilityand is therefore less likely to be corrupted at normal temperatures. Thehigher magnetic stability allows data to be dedicated to smaller cellson the disk media to increase the storage density. A focused light, suchas a laser, near-field optical source, or other rapid heating source, isused to selectively heat small sections of the surface of the disk totemporarily lower the coercivity of the disk media just prior towriting. After being written to, the small portions of the disk cool toa more magnetically stable state.

HAMR technology, however, requires a laser or other rapid heatingcomponent to be deployed in proximity to the read/write transducer onthe head suspension. Other types of EAMR likewise require an elementthat selectively changes the coercivity of the disk media to be mountedon the head suspension. This places further demands on the highperformance components of the head suspension. Various embodiments ofthe present disclosure concern head suspension configurations that canaccommodate EAMR and/or other components on a head suspension.

SUMMARY OF THE INVENTION

Various embodiments concern a suspension assembly of a disk drive. Thesuspension comprises one or more transducers configured to one or bothof write to the media and read from the media and a flexure, the one ormore transducers supported by the flexure. The suspension assemblyfurther includes a load beam, the load beam comprising a major planararea formed from a substrate, the load beam further comprising a void inthe substrate, a dimple formed from the substrate, and a flange. Theflange is a region of the major planar area that extends partiallyaround the dimple but does not extend along an edge of the dimple. Thedimple and the void are positioned on the load beam such that the edgeof the dimple is adjacent to the void and the dimple is in contact withthe flexure and is configured to transfer a force to the flexure whileallowing the flexure to move relative to the load beam. The dimple cancomprise a spherical indentation and a transition section that isbetween the spherical indentation and the major planar area, thetransition section at least partially surrounding the sphericalindentation. In some embodiments, the transition section is at leastpartially truncated by the void along the edge of the dimple. In somefurther embodiments, the spherical indentation is at least partiallytruncated by the void along the edge of the dimple. In some embodiments,one or both of the transition section and the spherical indentationproject into the void. The void can be a window. A HAMR block or otherelement can extend through the window. The lack of a full flange canminimize the necessary clearance between the dimple and the HAMR blockor other element and thereby allow the window to be enlarged toaccommodate the HAMR block or other element.

Various embodiments concern methods of making a suspension assembly.Such methods can include forming a load beam from a substrate, the loadbeam comprising a major planar area. Such methods can further includeforming a void and a dimple in the substrate of the load beam. Thedimple can be formed to have a flange, the flange comprising a region ofthe major planar area that extends partially around the dimple but doesnot extend along an edge of the dimple. The dimple can be formed on theload beam such that the edge of the dimple is adjacent to the void.

Various embodiments concern a suspension assembly of a disk drivecomprising a load beam and a flexure mounted as a cantilever along theload beam. Either of the flexure or load beam comprises a dimple, aflange that extends partially around the dimple but does not extendalong an edge of the dimple, and a void that is adjacent to the edge ofthe dimple. The other of the flexure or the load beam comprises asurface with which the dimple is engaged to transfer a force between theload beam and the flexure while allowing movement between the flexureand the load beam.

While multiple embodiments are disclosed, still other embodiments of thepresent invention will become apparent to those skilled in the art fromthe following detailed description, which shows and describesillustrative embodiments of the invention. Accordingly, the drawings anddetailed description are to be regarded as illustrative in nature andnot restrictive. While the invention is amenable to variousmodifications and alternative forms, specific embodiments have beenshown by way of example in the drawings and are described in detailbelow. The intention, however, is not to limit the invention to theparticular embodiments described. On the contrary, the invention isintended to cover all modifications, equivalents, and alternativesfalling within the scope of the invention as defined by the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top planar view of a disk drive having a head suspensionassembly positioned over a magnetic disk.

FIG. 2 is an exploded view of a head suspension assembly.

FIG. 3 is a perspective view of a distal portion of a head suspensionassembly.

FIG. 4 is a side view of a distal portion of a head suspension assembly.

FIG. 5A is a perspective view of a load point dimple.

FIG. 5B is a plan view of the load point dimple of FIG. 5A.

FIG. 5C is a cross sectional view of the load point dimple of FIG. 5Balong line AA.

FIG. 6A is a perspective view of a forming pin and die for forming adimple.

FIG. 6B is a cross sectional view of the forming pin and the die of FIG.6A.

FIG. 7A is a plan view of a partially flangeless dimple on a load beam.

FIG. 7B is a perspective view of the partially flangeless dimple of FIG.7A.

FIG. 7C is a cross sectional view of the partially flangeless dimple ofFIG. 7A along line BB.

FIG. 8A is a plan view of a partially flangeless dimple on a load beam.

FIG. 8B is a perspective view of the partially flangeless dimple of FIG.8A.

FIG. 8C is a cross sectional view of the partially flangeless dimple ofFIG. 8A along line CC.

FIG. 9A is a plan view of a partially flangeless dimple on a load beam.

FIG. 9B is a perspective view of the partially flangeless dimple of FIG.9A.

FIG. 9C is a cross sectional view of the partially flangeless dimple ofFIG. 9A along line DD.

FIG. 10A is a plan view of a partially flangeless dimple on a load beam.

FIG. 10B is a perspective view of the partially flangeless dimple ofFIG. 10A.

FIG. 10C is a cross sectional view of the partially flangeless dimple ofFIG. 10A along line EE.

FIG. 11A is a plan view of a partially flangeless dimple on a load beam.

FIG. 11B is a perspective view of the partially flangeless dimple ofFIG. 11A.

FIG. 11C is a cross sectional view of the partially flangeless dimple ofFIG. 11A along line FF.

FIG. 12A is a plan view of a partially flangeless dimple on a load beam.

FIG. 12B is a perspective view of the partially flangeless dimple ofFIG. 12A.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a plan view of a disk drive 2 having a head suspension 10suspended over a disk 4. The head suspension 10 supports a slider 22over the disk 4. The head suspension 10 is attached at its proximal endto an actuator arm 8, which is coupled to an actuator motor 6 mountedwithin the disk drive 2. The actuator motor 6 positions the actuator arm8, head suspension 10, and slider 22 over a desired position on the disk4. In the embodiment shown, the actuator motor 6 is rotary in nature,and operates to radially position the head suspension 10 and slider 22over the disk 4. Other actuator motors, such as a linear actuator motor,can alternatively be used.

In use, the slider 22 reads from and/or writes to the disk 4 while thehead suspension 10 supports and aligns the slider 22 over a desiredlocation on the disk 4 in response to signals received from amicroprocessor (not shown). The disk 4 rapidly spins about an axis, andan air bearing is created by the flow of air generated by the rapidlyrotating disk 4. The slider 22 is aerodynamically designed to “fly” onthe air bearing between the surface of the disk 4 and the slider 22. Theair bearing urges the slider 22 away from the surface of the disk 4. Thehead suspension 10 provides a gram load spring force that counteractsthe force of the air bearing and urges the slider 22 toward the surfaceof the disk 4. The separation distance at which these two forces arebalanced during operation is known as the “fly height” of the slider 22.The specific positional orientation of slider 22 provided by headsuspension 10 at the fly height in relation to the surface of the disk 4is commonly referred to as the “dynamic attitude” of the slider 22.

As shown in greater detail in FIG. 2, the head suspension 10 iscomprised of a plurality of separate components that are mountedtogether. Head suspension 10 includes a load beam 12 to which a flexure40 is mounted. The load beam 12 is a generally planar structure formedfrom a metal substrate, such as stainless steel. The load beam 12includes a major planar area (e.g., a top or bottom surface of the loadbeam 12) that is flat and extends over a large portion of the load beam12. The load beam 12 is generally rigid such that the different sectionsof the major planar area do not move relative to one another duringnormal operation of the head suspension 10. The major planar area isinterrupted by various features, such as the proximal window 32 and thedistal window 34. Other windows are shown in the load beam 12. Thewindows are open on a first side (e.g., the top side) and a second side(e.g., the bottom side) of the load beam 12 by extending through thesubstrate of the load beam 12. The windows can be used for alignmentduring assembly, the windows can lighten and/or strengthen the load beam12, and/or other components can extend through one or more of thewindows, as further discussed herein.

The load beam 12 includes a mounting region 13 at its proximal end, towhich a base plate 14 is mounted. The mounting region 13 and base plate14 are mounted to the actuator arm 8 of disk drive 2 in a known manner.The load beam 12 further includes a rigid region 24 at the distalportion of the load beam 12 and a spring region 20 located proximal ofthe rigid region 24 and distal of the mounting region 13. A flexure 40(discussed more fully below) is mounted to the rigid region 24 of theload beam 12 and provides a resilient connection between the load beam12 and slider 22.

The spring region 20 of load beam 12 provides a desired gram load thatopposes the force exerted upon the slider 22 by the air bearinggenerated by the rotating disk 4. Toward this end, the spring region 20can include a preformed bend or radius that provides a precise gram loadforce. The gram load is transmitted to the flexure 40 through the rigidregion 24 of the load beam 12. A dimple 9 extends between the rigidregion 24 of the load beam 12 and the flexure 40 to provide a point oftransfer for the gram load.

The flexure 40 provides a resilient connection between the slider 22 andthe load beam 12, and is designed to permit the slider 22 to gimbal inresponse to variations in the air bearing generated by the rotating disk4. That is, minute variations in the surface of the disk 4 will createfluctuations in the air bearing generated by the rotating disk 4. Thesefluctuations in the air bearing will cause the slider 22 to roll about alongitudinal axis 11 (e.g., X-axis) of the head suspension 10, and topitch about a transverse axis 15 (e.g., Y-axis). The flexure 40 isdesigned to permit the slider 22 to gimbal in both pitch and rolldirections in response to these air bearing variations. The dimple 9provides a point about which the slider 22, attached to the flexure 40in a cantilevered manner, can gimbal in response to fluctuations in theair bearing to allow the slider 22 to pitch and roll relative to theload beam 12. Specifically, the spring arms 30 allow the tongue orcantilever beam 26 of the flexure 40 to gimbal in pitch and rollmovements to accommodate surface variations in the disk 4 over which theslider 22 flies.

In the embodiment shown, the flexure 40 is separately formed from theload beam 12 such that the head suspension 10 is a three-piece designcomprising the base plate 14, the load beam 12, and the flexure 40. Theflexure 40 includes a mounting region 42 that overlaps and is mounted tothe rigid region 24 of the load beam 12 using spot welds or otherattachment techniques. The flexure 40 also includes a gimbal region 44that can extend beyond the distal end of the load beam 12 and that canprovide the resilient compliances that permits the slider 22 to gimbal.The gimbal region 44 comprises a pair of longitudinally extending springarms 30 that are connected at the distal end of the spring arms 30 by across piece 28. The longitudinally extending spring arms 30 and thecross piece 28 define a gap between the spring arms 30 into which atongue or cantilever beam 26 proximally extends from cross piece 28. Thetongue or cantilever beam 26 includes a slider mounting surface 27 towhich the slider 22 is mounted using known techniques such as adhesive.The tongue or cantilever beam 26 and spring arms 30 are sufficientlyresilient to pitch about axis 15 and to torsionally rotate about axis 11to permit pitch and roll motion of the slider 22 as needed duringoperation of the disk drive 2.

The flexure 40 also includes a trace assembly 50 that provideselectrical interconnection between the slider 22 and a microprocessor(not shown) of the disk drive 2 to convey read and write signals to andfrom transducers mounted on the slider 22. The trace assembly 50 of theshown embodiment is comprised of a conductive layer 52 formed intolongitudinal traces that extend along the length of the flexure 40 andan insulating layer 54 interposed between the spring metal layer 31 andthe conductive layer 52. The trace assembly 50 can alternatively beformed separately from the rest of the flexure 40 and then mounted tothe rest of the flexure 40 in a known method, such as with the use ofadhesive. The trace assembly 50 can be routed across the flexure in anynumber of desired patterns as dictated by a specific application. In theembodiment shown in FIG. 2, the trace assembly 50 at the gimbal region44 of the flexure 40 is adjacent to, and spaced apart from, the springarms 30 of the flexure 40. During normal operation of the disk drive 2,the slider 22 assumes an orientation over the surface of the rotatingdisk 4 (the dynamic attitude) at a specific separation distance (e.g.,0.01 micrometers) from the surface of the disk 4.

FIG. 3 shows a perspective view of the head suspension 10 in anassembled state. Specifically, FIG. 3 shows the top side of the headsuspension 10. The slider 22 is on the bottom side of the headsuspension 10 and is not visible in FIG. 3. FIG. 4 illustrates a sideview of the head suspension 10. FIGS. 3 and 4 show a HAMR block 46. TheHAMR block 46 can include components for generating focused light, suchas a laser diode structure, for selectively heating the surface of thedisk 4. Alternative components can be included in the HAMR block 46 orsimilar structure, whether related to EAMR technology or providing otherfunctionality. As such, while HAMR technology and a HAMR block arereferenced specifically herein, each of the embodiments of the presentdisclosure could alternatively include an EAMR block or other element ofsimilar or different dimensions and functionality. The HAMR block 46 canbe attached to the slider 22. One or more magnetic transducers can bemounted on a first side of the slider 22 while the HAMR block 46 can bemounted on a second side of the slider 22. The first side of the slider22 can be opposite the second side. The HAMR block 46 can be bonded to aside of the slider 22 along a trailing edge to facilitate heatapplication coincidentally with the one or more transducers. The HAMRblock 46 can be substantial in size (e.g., spanning 0.2 mm by 0.5 mm infootprint and spanning 0.2 mm or greater in height). In response, and asshown in FIG. 3, the HAMR block 46 extends through the distal window 34of the load beam 12 and through the flexure 40. Being that the HAMRblock 46 extends through the load beam 12 and the flexure 40, clearancebetween the HAMR block 46 and the internal edges of the windows of theload beam 12 and the flexure 40 may be required. In particular,clearance along the X-Y plane (e.g., co-planar with the major planararea of the load beam 12) may be required around the HAMR block 46. Forexample, clearances of 0.050 mm or more may be required of features ofboth the flexure 40 and the load beam 12. One feature about whichsufficient clearance may be necessary is the dimple 9, which is shown inFIGS. 2-4 and is further discussed herein.

FIG. 4 shows that the load beam 12 and flexure 40 are attached to oneanother proximally but divide into different structures distally. Inthis way, the flexure 40 is cantilevered from the load beam 12. As shownin FIG. 4, the dimple 9 interfaces with the flexure 40. The roundedshape of the dimple 9 allows the flexure 40 and other components mountedon the flexure 40, such as the slider 22 and HAMR block 46, to pitch androll relative to the load beam 12.

A discussion of dimples as used in suspension assemblies will bebeneficial for understanding aspects of the present invention. FIGS.5A-C show a dimple 55. Specifically, FIG. 5A shows a perspective view ofthe dimple 55, FIG. 5B shows a plan view of the dimple 55, and FIG. 5Cshows a cross sectional view of the dimple 55 along line AA of FIG. 5B.The dimple 55 is formed from the substrate 51 of a load beam. The dimple55 can be located within a major planar area of a load beam.

The dimple 55 has a protruding surface on a first side 23 of thesubstrate 51 and a recessed surface on a second side 25 of the substrate51 that is opposite the first side 23. The dimple 55 includes an apex29, which is the highest point of the dimple 55. The dimple 55 includesseveral different sections. Specifically, the dimple 55 includes aspherical indentation 56 and a transition section 57. The transitionsection 57 fully encircles the spherical indentation 56 and is adjacentto the spherical indentation 56. The spherical indentation 56 has asubstantially uniform spherical curvature while the transition section57 has a curvature that is different from the spherical indentation 56.Specifically, the transition section 57 transitions the curvature of thedimple 55 from the substantially uniform spherical curvature to the flatprofile of the flange 58.

In some embodiments, the height of the dimple 55, as measured from thesurface of the first side 23 of the substrate 51 to the apex 29, is0.050 mm. The radius of curvature of the spherical indentation 56 canbe, for example, 0.200 mm. The radius of curvature for a portion of thetransition section 57 can be, for example, 0.012 mm. The thickness ofthe substrate can be, for example, 0.025 mm. However, larger and smallerdimensional values than those listed are also contemplated. It is notedthat the Figs. shown herein may not be to scale and that some portions,such as the relative size of the transition section 57, may appear asexaggerated herein for the purpose of illustration of the variouscomponents.

The dimple 55 is fully surrounded by the flange 58 in the embodiment ofFIGS. 5A-C. A flange, as referenced herein, is a planar section of asubstrate (e.g., of a load beam or a flexure) that is adjacent to atleast a portion of a dimple. As shown in FIG. 5B, the flange 58peripherally encircles both of the spherical indentation 56 and thetransition section 57 while being directly connected with the transitionsection 57 by virtue of being formed for the same substrate 51. Thediameter of the flange 58 can be a “best practice” preferred value of0.381 mm plus three times the thickness of the substrate 51. As shown inFIG. 5C, the substrate 51 is a sheet of material (e.g., metal,preferably stainless steel) that is integral and continuous along thedimple 55, the flange 58, and the major planar area 59. As indicated inFIGS. 5A-C, the flange 58 is a subportion of the major planar area 59.The flange 58 is formed from the same substrate 51 as the sphericalindentation 56, the transition section 57, and the major planar area 59and has the same thickness as the major planar area. The flange 58 cancorrespond to the area of the substrate 51 adjacent to the dimple 55that is directly engaged with a clamp during the process of forming (viadeformation of the substrate 51) the dimple 55, as further discussedherein. The flange 58 allows for clamping of the substrate 51 materialduring the formation of the dimple 55. The flange 58 is adjacent to thedimple 55 but is not part of the dimple 55 itself and is not deformedduring the formation of the dimple 55.

The portion of the substrate 51 from which the spherical indentation 56and the transition section 57 are formed is uniform with the majorplanar area 59 before that portion is indented. The transition section57 transitions the profile of the substrate 51 from the planar profileof the flange 58 to the curved profile of the spherical indentation 56.As such, the flange 58 is flat and does not include a bending shape orprofile, while the transition section 57 includes a bending profile thatis different in curvature from the bending profile of the sphericalindentation 56. The outer transition boundary 49 represents the bottomedge of the indentation where the substrate 51 first makes thetransition from the flat planer surface of the flange 58 and begins totransition along a tight radius leading, eventually, into the profile ofthe spherical indentation 56. The outer spherical indentation boundary53 represents the completion of the tight side transition and the startof the larger spherical radius of the spherical indentation 56. Whilethe outer transition boundary 49 and the outer spherical indentationboundary 53 form full circles (e.g., in an X-Y plane) around thespherical indentation 56, as viewed from the plan view perspective ofFIG. 5B, full circles may not be formed by similar outer transitionboundaries and the outer spherical indentation boundaries in some otherembodiments as further discussed herein.

FIGS. 6A-B illustrate tooling for formation of a dimple. Specifically,FIG. 6A shows a perspective view of a forming pin 37 and a lower clamp39. The lower clamp 39 includes a socket 36. The socket 36 can be a diethat forms the shape of a spherical indentation together with thespherical distal end of the forming pin 37. The lower clamp 39 can beplanar while the socket 36 can include a negative of the sphericalindentation for forming the dimple. The substrate 51, in planar form(i.e. pre-indentation), can be placed on the lower clamp 39. FIG. 6Bshows a cross sectional view of lower clamp 39 and an upper clamp 38.The substrate 51 is held between the lower clamp 39 and the upper clamp38. Specifically, the lower clamp 39 and the upper clamp 38 engageopposite sides of the substrate 51 along the flange 58. When clamped,the forming pin 37 can be pressed into the substrate 51 to plasticallydeform the substrate 51 and form the dimple 55. Specifically, thesubstrate 51 is deformed to have a spherical indentation 56 and atransition section 57 while the flange 58, being clamped, is notdeformed by this process. Any dimple referenced herein can be formed inthe same manner and can have the same features as the dimple 55 of FIGS.5A-C or as described above, except for modifications as furtherdiscussed herein.

Returning to FIGS. 5A-C, it is noted that the flange 58 fully surroundsthe transition section 57 and the spherical indentation 56 because thetargeted placement of the dimple 55 (e.g., via the forming process ofFIGS. 6A-B) was a sufficient distance from any other feature of thesubstrate 51 (e.g., a window or other type of void in the substrate 51)that a planar region of undeformed substrate 51 was left to fullyencircled the dimple 55. In some load beams, to accommodate the flange58 in fully surrounding the transition section 57 and the sphericalindentation 56, the apex of a dimple might be located 0.228 mm from anedge of a window or other feature, wherein the flange 58 may otherwiseoverlap with the window to leave a discontinuity in the flange 58. Assuch, the flange 58 of FIGS. 5A-C can be fully formed by allowing aminimum distance between the dimple 55 (e.g., the apex or center of thedimple 55) and any other feature of a load beam. However, leaving a fullflange 58 takes up precious space on the lead beam.

As previously discussed, the addition of HAMR components, such as a HAMRblock 46 extending through the distal window 34 as shown in FIGS. 3-4,places a greater need on enlarging the distal window 34 so that thedistal window 34 can accommodate the HAMR block 46 or other feature.However, the provision of a flange 58 that fully surrounds the sphericalindentation 56 limits the degree to which the distal window 34 can beenlarged before the proximal edge of the distal window 34 overlaps thefull flange 58. The inventors of the subject matter of the presentdisclosure have determined that a dimple can be formed without part of aflange while still maintaining the structural integrity and function ofthe dimple. Accordingly, various embodiments of the present disclosureconcern forming dimples such that the flanges do not fully surround thedimples. Such embodiments are further discussed herein.

FIG. 7A shows a plan view of a load beam 70 while FIG. 7B shows aperspective view of a portion of the load beam 70. FIG. 7C shows a crosssectional view along line BB of FIG. 7A. The load beam 70 can be formedsimilarly to any other embodiment disclosed herein except where noted.The load beam 70 is generally planar and includes a major planar area 74that extends over much of the load beam 70 (e.g., half or more of thesurface area of a top or bottom side of the load beam 70, however thecoverage may be less in some embodiments). The load beam 70 includes aproximal window 72. The load beam 70 also includes a distal window 71through which a HAMR block or other element can extend, however such aHAMR block is not shown in FIG. 7B for clarity. The distal window 71includes a proximal edge 75. The distal window 71 is fully enclosedwithin the major planar area 74 of the load beam 70 (i.e. the distalwindow 71 does not include a side opening in the X-Y plane). The loadbeam 70 further includes a dimple 73 that is only partially surroundedby a flange 78. The flange 78 is a region of the major planar area 74that extends partially around the dimple 73, but does not extend along adistal edge 79 of the dimple 73. For example, the flange 78 is adjacentto the proximal side and the lateral sides of the dimple 73 while thedistal edge 79 of the dimple 73 is adjacent to the distal window 71. Thedistal edge 79 faces into the window 71 or otherwise defines an edge ofthe distal window 71. The distal edge 79 of the dimple 73 extends from aleft distal truncation of the flange 78 to a right distal truncation ofthe flange 78. The flange 78 extends around the proximal side and thelateral sides of the transition section 77 of the dimple 73 but theflange 78 terminates at the proximal edge 75 such that the flange 78does not extend along the distal edge 79 of the transition section 77.The absence of the flange 78 along the distal edge 79 of the dimple 73allows the distal window 71 to be enlarged past where the flange 78would have otherwise been, and as such the absence of the flange 78along the distal edge 79 of the dimple 73 allows the load beam 70 toaccommodate a HAMR block or other component or otherwise allows for amore compact configuration. Use of a partially flangeless dimple asdescribed herein can result in a clearance between the distal edge 79and a HAMR block of 0.139 mm in some embodiments.

It is noted that the radius of the transition section 77 (e.g., asmeasured from the center of the spherical indentation 76) is notconsistent peripherally around the dimple 73. Specifically, thetransition section 77 has a relatively larger radius along the proximalside and the lateral sides of the transition section 77 and a relativelysmaller radius along the distal side of the transition section 77. Asshown in FIGS. 7A-B, the transition section 77 is partially truncated atthe proximal edge 75 such that a limited portion of the transitionsection 77 projects past the proximal edge 75 and into the distal window71. In some other embodiments, the transition section 77 is nottruncated at the proximal edge 75 such that the full radius of thetransition section 77 projects past the proximal edge 75 and into thedistal window 71. In some other embodiments, the transition section 77is fully truncated at the proximal edge 75 such that no part of thetransition section 77 projects past the proximal edge 75 into the distalwindow 71. In such cases, the proximal edge 75 may be linear between thelateral edges of the distal window 71. In any case, the sphericalindentation 76 is not truncated in the illustrated embodiment.

As shown, the transition section 77 of the dimple 73 extends distally ofthe proximal edge 75 of the distal window 71, thereby projecting intothe distal window 71. In this way, the proximal edge 75 is not linearbetween the lateral edges of the distal window 71. The distal edge ofthe spherical indentation 76 does not extend distally of the proximaledge 75 of the distal window 71 in the embodiment shown in FIGS. 7A-C.In some embodiments, the distal edge of the spherical indentation 76 isaligned with the proximal edge 75 of the distal window 71 while in someother embodiments the distal edge of the spherical indentation 76terminates distally of the proximal edge 75. In some other embodiments,the spherical indentation 76 extends distally of the proximal edge 75,thereby projecting into the distal window 71.

FIG. 8A shows a plan view of a load beam 80 while FIG. 8B shows aperspective view of a portion of the load beam 80. FIG. 8C shows a crosssectional view along line CC of FIG. 8A. The load beam 80 can be formedsimilarly to any other embodiment disclosed herein except where noted.The load beam 80 is generally planar and includes a major planar area 85that extends over much of the load beam 80. The load beam 80 includes aproximal window 82. The proximal window 82 includes a distal edge 84.The proximal window 82 is fully enclosed within the major planar area 85of the load beam 80 (i.e. the proximal window 82 does not include a sideopening). The load beam 80 further includes a dimple 83 that is onlypartially surrounded by a flange 88. The flange 88 is a region of themajor planar area 85 that extends partially around the dimple 83, butdoes not extend along a proximal edge 89 of the dimple 83. For example,the flange 88 is adjacent to the distal side and the lateral sides ofthe dimple 83 while the proximal edge 89 of the dimple 83 is adjacent tothe proximal window 82. The proximal edge 89 faces into the proximalwindow 82 or otherwise defines an edge of the proximal window 82. Theproximal edge 89 of the dimple 83 extends from a left proximaltruncation of the flange 88 to a right proximal truncation of the flange88. The flange 88 extends around the distal side and the lateral sidesof the transition section 87 of the dimple 83, but the flange 88terminates at the distal edge 84 such that the flange 88 does not extendalong the proximal side of the transition section 87. The absence of theflange 88 along the proximal side of the dimple 83 allows the proximalwindow 82 to be enlarged past where the flange 88 would have otherwisebeen, and as such the absence of the flange 88 along the proximal sideof the dimple 83 allows the proximal window 82 to accommodate componentsor otherwise allows for a more compact configuration.

It is noted that the radius of the transition section 87 is consistentperipherally around the entire dimple 83. However, the proximal side ofthe transition section 87 could be modified to be radially smaller thanthe distal side of the transition section 87. In some cases, a portionof the proximal side of the transition section 87 can be truncated in asimilar manner as the distal side of the transition section 77 of FIGS.7A-B. In some other embodiments, the transition section 87 is fullytruncated at the distal edge 84 such that no part of the transitionsection 87 projects past the distal edge 84 into the proximal window 82.In such cases, the distal edge 84 may be linear between the lateraledges of the proximal window 82.

As shown, the transition section 87 of the dimple 83 extends proximallyof the distal edge 84 of the proximal window 82, thereby projecting intothe proximal window 82. In this way, the distal edge 84 is not linearbetween the lateral edges of the proximal window 82. The proximal edgeof the spherical indentation 86 does not extend proximally of the distaledge 84 of the proximal window 82 in the embodiment shown in FIGS. 8A-B.In some embodiments, the proximal edge of the spherical indentation 86is aligned with the distal edge 84 of the proximal window 82. In someother embodiments, the spherical indentation 86 extends proximally ofthe distal edge 84, thereby projecting into the proximal window 82.

FIG. 9A shows a plan view of a load beam 90 while FIG. 9B shows aperspective view of a portion of the load beam 90. FIG. 9C shows a crosssectional view along line DD of FIG. 9A. The load beam 90 can be formedsimilarly to any other embodiment disclosed herein except where noted.The load beam 90 is generally planar and includes a major planar area 35that extends over much of the load beam 90. The load beam 90 includes adistal window 91 through which a HAMR block can extend. The distalwindow 91 includes a proximal edge 95. The load beam 90 also includes aproximal window 92. The proximal window 92 includes a distal edge 94.The load beam 90 further includes a dimple 93 that is partiallysurrounded by a flange 98. The flange 98 extends around the lateralsides of the transition section 97 of the dimple 93 but the flange 98terminates at the proximal edge 95 and the distal edge 94 such that theflange 98 does not extend along the distal side or the proximal side ofthe dimple 93. The flange 98 is a region of the major planar area 35that extends partially around the dimple 93 but does not extend along adistal edge 99 of the dimple 93 such that the distal edge 99 of thedimple 93 is adjacent to the distal window 91. In some alternativeembodiments, the flange 98 may not extend along the proximal edge 95 ofthe dimple 93.

The radius of the transition section 97 is not consistent peripherallyaround the dimple 93. Specifically, the transition section 97 has arelatively larger radius along the proximal side and the lateral sidesof the transition section 97 and a relatively smaller radius along thedistal side of the transition section 97. As shown in FIGS. 9A-B, thetransition section 97 is partially truncated at the proximal edge 95such that a limited portion of the transition section 97 projects pastthe proximal edge 95 and into the distal window 91. In some otherembodiments, the transition section 97 is not truncated at the proximaledge 95 such that the full radius of the transition section 97 projectspast the proximal edge 95 and into the distal window 91. In some otherembodiments, the transition section 97 is fully truncated at theproximal edge 95 such that no part of the transition section 97 projectspast the proximal edge 95 into the distal window 91. In such cases, theproximal edge 95 may be linear between the lateral edges of the distalwindow 91.

The transition section 97 of the dimple 93 extends distally of theproximal edge 95 of the distal window 91, thereby projecting into thedistal window 91. The distal edge of the spherical indentation 96 doesnot extend distally of the proximal edge 95 of the distal window 91 inthe embodiment shown in FIGS. 9A-B. In some embodiments, the distal edgeof the spherical indentation 96 is aligned with the proximal edge 95 ofthe distal window 91 while in some other embodiments the distal edge ofthe spherical indentation 96 terminates distally of the proximal edge95. In some other embodiments, the spherical indentation 96 extendsdistally of the proximal edge 95, thereby projecting into the distalwindow 91.

In some cases, a portion of the proximal side of the transition section97 can be truncated in a similar manner as the distal side of thetransition section 97. In some other embodiments, the transition section97 is fully truncated at the distal edge 94 such that no part of thetransition section 97 projects past the distal edge 94 into the proximalwindow 92. In such cases, the distal edge 94 may be linear between thelateral edges of the proximal window 92.

The transition section 97 of the dimple 93 extends proximally of thedistal edge 94 of the proximal window 92, thereby projecting into theproximal window 92. In this way, the distal edge 94 is not linearbetween the lateral edges of the proximal window 92. The distal edge ofthe spherical indentation 96 does not extend proximally of the distaledge 94 of the proximal window 92 in the embodiment shown in FIGS. 9A-B.In some embodiments, the distal edge of the spherical indentation 96 isaligned with the distal edge 94 of the proximal window 92. In some otherembodiments, the spherical indentation 96 extends proximally of thedistal edge 94, thereby projecting into the proximal window 92.

FIG. 10A shows a plan view of the load beam 100 while FIG. 10B shows aperspective view of a portion of the load beam 100. FIG. 10C shows across sectional view along line EE of FIG. 10A. The load beam 100 can beformed similarly to any other embodiment disclosed herein except wherenoted. The load beam 100 is generally planar and includes a major planararea 104 that extends over much of the load beam 100. The load beam 100includes a proximal window 102. The load beam 100 also includes a distalwindow 101 through which a HAMR block or other element can extend. Thedistal window 101 includes a proximal edge 105. The load beam 100further includes a dimple 103 that is partially surrounded by flange108. The flange 108 is a region of the major planar area 104 thatextends partially around the dimple 103 but does not extend along adistal edge 109 of the dimple 103 such that the distal edge 109 of thedimple 103 is adjacent to the distal window 101. The distal edge 109 ofthe dimple 103 extends from a left distal truncation of the flange 108to a right distal truncation of the flange 108. The flange 108 extendsaround the proximal side and the lateral sides of the transition section107 of the dimple 103, but the flange 108 terminates at the proximaledge 105 such that the flange 108 does not extend along the distal sideof the transition section 107. The absence of the flange 108 along thedistal side of the dimple 103 allows the distal window 101 to beenlarged past where the flange 108 would have otherwise been, and assuch the absence of the flange 108 along the distal side of the dimple103 allows the load beam 100 to accommodate a HAMR block or othercomponent or otherwise allows for a more compact configuration.

It is noted that the spherical indentation 106 is truncated such thatthe spherical indentation 106 does not extend past the proximal edge 105of the distal window 101. In this way, the proximal edge 105 is linearbetween the lateral edges of the distal window 101. It is noted that theapex of the dimple 103 (i.e., the highest point of the dimple 103) isstill present to provide a contact point with the flexure 40. However,the spherical indentation 106 is truncated such that the distal edge ofthe spherical indentation 106 coincides with the proximal edge 105 for aportion of the proximal edge 105 and the proximal edge 105 is raisedalong the portion relative to the major planar area 104.

The termination of the dimple 103 creates a lateral cutout in thespherical indentation 106 such that the spherical indentation 106 is nota complete dome having a full circular outer profile. For example, thespherical indentation 106 is asymmetric. The lateral cutout along thecurvature of the spherical indentation 106 causes the proximal edge 105of the distal window 101 to be curved upward, as shown in FIG. 10B. Inother words, the proximal edge 105 of the distal window 101 is raisedalong the spherical indentation 106 but is flat laterally of the dimple103 and level with the major planar area 104. It is noted that thedistal window 101 can be expanded or moved distally and/or the sphericalindentation 106 can be moved proximally to create a larger cutout of thespherical indentation 106. In some cases, the distal edge of thespherical indentation 106 (i.e., the proximal edge 105 of the distalwindow 101) is adjacent to, and distal of, the apex of the sphericalindentation 106 such that almost half of the spherical indentation 106is absent. In some embodiments, the truncation of the dimple 103 reducesthe footprint of the spherical indentation 106 (e.g., in the X-Y planeor as viewed from a plan perspective) by 30-40% relative to a fullspherical indentation as shown elsewhere herein.

While the distal edge of the spherical indentation 106 coincides withthe proximal edge 105 such that the spherical indentation 106 does notproject into the distal window 101 in the illustrated embodiment, thespherical indentation 106 can project into the distal window 101 whilestill being truncated in some other embodiments. Likewise, thetransition section 107 can project into the distal window 101 whilestill being truncated. In such alternative embodiments, the transitionsection 107 does not extend fully around the spherical indentation 106and/or the transition section 107 has an inconsistent radius around theperiphery of the spherical indentation 106.

The truncation of the spherical indentation 106 and the transitionsection 107 can occur by first forming a full spherical indentation andthen selectively removing a portion of the spherical indentation 106(e.g., by etching or cutting). The removal step can be performed whenforming the distal window 101 and/or while or after forming the dimple103. In some other embodiments, the spherical indentation 106 andtransition section 107 are formed, as truncated, by indenting thesubstrate at a location proximate the distal window 101 such that theproximal edge 105 extends through the socket of the die that forms thespherical indentation 106. Any embodiment referenced herein can befabricated similarly.

FIG. 11A shows a plan view of a load beam 110 while FIG. 11B shows aperspective view of a portion of the load beam 110. FIG. 11C shows across sectional view along line FF of FIG. 11A. The load beam 110 can beformed similarly to any other embodiment disclosed herein except wherenoted. The load beam 110 is generally planar and includes a major planararea 114 that extends over much of the load beam 110. The load beam 110includes a proximal window 112. The load beam 110 also includes a distalwindow 111 through which a HAMR block or other component can extend. Thedistal window 111 includes a proximal edge 115. The load beam 110further includes a dimple 113 that is partially surrounded by flange118. The flange 118 is a region of the major planar area 114 thatextends partially around the dimple 113 but does not extend along adistal edge 119 of the dimple 113 such that the distal edge 119 of thedimple 113 is adjacent to the distal window 111. The distal edge 119 ofthe dimple 113 extends from a left distal truncation of the flange 118to a right distal truncation of the flange 118. The flange 118 extendsaround the proximal side and partially along the lateral sides of thetransition section 117 of the dimple 113. The flange 118 terminates atthe proximal edge 115 such that the flange 118 does not extend along thedistal side of the transition section 117.

The dimple 113 extends distally of the proximal edge 115 of the distalwindow 111, thereby projecting into the distal window 111. Specifically,both of the spherical indentation 116 and the transition section 117extend distally of the proximal edge 115 and into the distal window 111.As shown in FIGS. 11A-B, the apex of the spherical indentation 116 isaligned with the proximal edge 115 of the distal window 111. In someother embodiments, the apex of the spherical indentation 116 can bedistal of the proximal edge 115 of the distal window 111 such that amajority of the spherical indentation 116 (e.g., by surface area ormass) projects into the distal window 111. In yet further embodiments,the apex of the spherical indentation 116 can be proximal of theproximal edge 115 of the distal window 111 such that a majority of thespherical indentation 116 is proximal of the proximal edge 115.

The spherical indentation 116 is not truncated in the embodiment ofFIGS. 11A-B. In this way, the spherical indentation 116 comprises a fullcircular profile. In some other embodiments, the spherical indentation116 can be truncated such that the spherical indentation 116 does notdefine a full circular profile. For example, even though a portion ofthe spherical indentation 116 can extend distally of the proximal edge115 and into the distal window 111, a distal section of the sphericalindentation 116 can nevertheless be truncated, the truncation of thespherical indentation 116 distal of the proximal edge 115.

The radius of the transition section 117 is not consistent peripherallyaround the dimple 113. Specifically, the transition section 117 has arelatively larger radius along the proximal side and the lateral sidesof the transition section 117 and a relatively smaller radius along thedistal side of the transition section 117. As shown in FIGS. 11A-B, thetransition section 117 is partially truncated at the proximal edge 115such that a limited portion of the transition section 117 projects pastthe proximal edge 115 and into the distal window 111. In someembodiments, the truncation of the flange 118 extends proximally to theapex of the spherical indentation 116.

In some other embodiments, the transition section 117 is not truncatedat the proximal edge 115 such that the full radius of the transitionsection 117 projects past the proximal edge 115, into the distal window111, and around the distal side of the transition section 117. In someother embodiments, the transition section 117 is fully truncated at theproximal edge 115 such that no part of the transition section 117projects past the proximal edge 115 into the distal window 111. In suchcases, the proximal edge 115 may be linear between the lateral edges ofthe distal window 111.

FIG. 12A shows a plan view of a load beam 120 while FIG. 12B shows adetailed view of a portion of the load beam 120. The load beam 120 canbe formed similarly to any other embodiment disclosed herein exceptwhere noted. While previous embodiments have shown load beams havingwindows as a type of void along which a dimple and/or flange canterminate and of which the dimple is accordingly adjacent to andoptionally projects therein, the load beam 120 of FIGS. 12A-B has adimple 123 that extends into another type of void 121. The void 121 inthis case is a cutout in the load beam 120 that allows components of thehead suspension to move relative to one another. For example, the springarms 124 allow the proximal portion 122 of the load beam 120 to moverelative to a distal portion 126 of the load beam 120. The void 121separates the proximal portion 122 from the distal portion 126. Thedimple 123 can function as a load point that allows pitch and roll offlexure.

As shown in FIG. 12B, the dimple 123 extends from the proximal portion122 of the load beam 120. A flange 128, connecting the dimple 123 to theload beam 120, is provided only along the proximal side of the dimple123. As such, the flange 128 does not extend along the lateral sides(left and right) or the distal side of the dimple 123. The transitionsection 127, which corresponds to the edge of the dimple 123 thattransitions the substrate from the planar profile of the proximalportion 122 to the spherical indentation 133 of the substrate, extendsonly along the proximal side of the dimple 123 and does not extend alongthe lateral sides or the distal side of the dimple 123. In some otherembodiments, the transition section 127 can extend along any of thelateral sides and the distal side of the dimple 123.

The spherical indentation 133 is truncated in the embodiment of FIG.12B. In this way, the spherical indentation 133 does not comprise a fullcircular profile. The truncation of the spherical indentation 133creates lateral truncated sides 130 and a distal truncated side 131,each of which is liner from an overhead profile along X-Y plane but iscurved in a Z-axis. In some other embodiments, the spherical indentation133 may not be truncated on one or more of the lateral sides or thedistal side which can change the curvature of the lateral sides 130 andthe distal side 131 from that shown. It is noted that the dimple 123extends distally of the distal edge 125 of the proximal portion 122 ofthe load beam 120. The distal edge 125 is not linear as shown in FIGS.12A-B, however the distal edge 125 can be linear in some alternativeembodiments.

It is noted that the additional clearance that a partial flange affordscould be used for applications other than EAMR technology. Additionalroom can be provided to accommodate other components of other forms ofEAMR including but not limited to additional sensors attached to thebackside of the slider, additional pads and/or terminations on the backside of the slider, a laser Doppler vibrometer, optical components, orother velocity and/or displacement measurement components on thebackside of a slider surface or gimbal tongue surface for gimbal orslider air bearing surface dynamics characterization, or other needsbenefiting from additional clearance.

It is noted that the concepts presented herein can be applied to anyvoid, including a window, such that any dimple configurationdemonstrated in one embodiment herein can be used in connection withanother embodiment. While load beam windows have been referenced hereinas exemplars, any void in the load beam or other component could besubstituted in any embodiment referenced herein. Also, while a sphericalindentation has been provided as an example herein for a load pointshape, it will be understood that other shapes could alternatively beformed in place of the spherical indentation in any embodimentreferenced herein.

Although the present invention has been described with reference topreferred embodiments, those skilled in the art will recognize thatchanges can be made in form and detail without departing from the spiritand scope of the invention. For example, the various features of theillustrated embodiments can be combined with features of otherembodiments. As such, the various embodiments disclosed herein can bemodified in view of the features of other embodiments, such as byomitting and/or adding features.

Various modifications and additions can be made to the exemplaryembodiments discussed without departing from the scope of the presentinvention. For example, while the embodiments described above refer toparticular features, the scope of this invention also includesembodiments having different combinations of features and embodimentsthat do not include all of the above-described features.

We claim:
 1. A suspension assembly of a disk drive, the suspensionassembly comprising: a flexure; and a load beam, the load beam formedfrom a substrate and comprising a major planar area, the load beamfurther comprising a void in the substrate, a dimple formed from thesubstrate, and a flange, wherein the flange is a region of the majorplanar area that extends partially around the dimple but does not extendalong an edge of the dimple, the edge of the dimple adjacent to thevoid, and the dimple is in contact with the flexure and is configured totransfer a force to the flexure while allowing the flexure to moverelative to the load beam.
 2. The suspension assembly of claim 1,wherein the dimple comprises a spherical indentation and a transitionsection that is between the spherical indentation and the flange, thetransition section at least partially surrounding the sphericalindentation.
 3. The suspension assembly of claim 2, wherein thetransition section is at least partially truncated by the void along theedge of the dimple.
 4. The suspension assembly of claim 2, wherein thetransition section is fully truncated by the void along the edge of thedimple such that the transition section does not extend along the edgeof the dimple.
 5. The suspension assembly of claim 4, wherein thespherical indentation is partially truncated by the void.
 6. Thesuspension assembly of claim 2, wherein the transition section projectsinto the void.
 7. The suspension assembly of claim 6, wherein thespherical indentation does not project into the void
 8. The suspensionassembly of claim 6, wherein the spherical indentation projects into thevoid.
 9. The suspension assembly of claim 1, wherein the dimple projectsinto the void.
 10. The suspension assembly of claim 1, wherein the voidis a window.
 11. The suspension assembly of claim 10, further comprisingan element that extends through the window, wherein the element issupported by the flexure.
 12. The suspension assembly of claim 11,wherein the element comprises at least part of a circuit that isconfigured to selectively change the coercively of disk media with heat.13. The suspension assembly of claim 11, wherein the clearance betweenthe apex of the dimple and the element is less than 0.150 millimeters.14. The suspension assembly of claim 1, further comprising one or moretransducers configured to read from disk media mounted on the flexure.15. The suspension assembly of claim 1, wherein the flange correspondsto a portion of the major planar area that is clamped when the dimple isformed by indenting the substrate.
 16. A method of making a suspensionassembly, the method comprising: forming a load beam from a substrate,the load beam comprising a major planar area; forming a void in thesubstrate; and forming a dimple in the substrate, the dimple formed tohave a flange, the flange comprising a region of the major planar areathat extends partially around the dimple but does not extend along anedge of the dimple, the dimple formed on the load beam such that theedge of the dimple is adjacent to the void.
 17. The method of claim 16,wherein forming the dimple comprises indenting the substrate with a dieand a forming pin.
 18. The method of claim 17, wherein forming thedimple comprises clamping the substrate along the flange while theforming pin indents the substrate to form the dimple.
 19. The method ofclaim 16, wherein forming the dimple comprises forming the dimple tohave a spherical indentation and a transition section that is betweenthe spherical indentation and the major planar area, the transitionsection at least partially surrounding the spherical indentation. 20.The method of claim 19, wherein the transition section is at leastpartially truncated at the void along the edge of the dimple.